Soft front cockpit cover

ABSTRACT

A soft panel top assembly for a vehicle in sealing engagement with a hard top portion of a roof. The soft panel top assembly has a fixed portion attached to the vehicle and a lightweight pivotal portion that folds back to provide a quick and easy open air effect. Two door rails of the soft panel top assembly are connected to the vehicle. Two side rail linkage assemblies are attached to the header, which is secured to a windshield frame when in a closed position, and are connected at pivot points created with a bracket attached to the door rails to allow the pivotal portion to pivot to an open position. The soft panel top assembly includes a rear header that is lightweight and has a sealing arrangement that engages with the hard top roof portion and existing seal of the hard top roof portion to provide a weatherproof seal.

CROSS-REFERENCE TO RELATED APPLICATIONS

The instant application is a continuation of U.S. patent applicationSer. No. 15/901,561, filed Feb. 21, 2018, which is a continuation ofU.S. patent application Ser. No. 15/276,386, filed Sep. 26, 2016, whichis a continuation-in-part of U.S. patent application Ser. No.14/831,414, filed Aug. 20, 2015, now U.S. Pat. No. 9,539,888, and acontinuation-in-part of U.S. patent application Ser. No. 14/808,011,filed Jul. 24, 2015, now U.S. Pat. No. 9,517,684, which U.S. patentapplication Ser. No. 14/831,414 is a continuation-in-part patentapplication of U.S. patent application Ser. No. 14/243,359, filed Apr.2, 2014, now U.S. Pat. No. 9,139,073, which claims the benefit of U.S.Provisional Application No. 61/807,506, filed Apr. 2, 2013, and U.S.patent application Ser. No. 14/808,011 is a continuation patentapplication of U.S. patent application Ser. No. 14/243,359, filed Apr.2, 2014, now U.S. Pat. No. 9,139,073, which claims the benefit of U.S.Provisional Application No. 61/807,506, filed Apr. 2, 2013, and U.S.application Ser. No. 15/276,386 is a continuation-in-part of U.S.application Ser. No. 15/128,773, filed Sep. 23, 2016, which is a 371 ofinternational Application No. PCT/US2015/022716, filed Mar. 26, 2015,which claims the benefit of U.S. Provisional Application No. 61/970,463,filed Mar. 26, 2014. The disclosures of the above applications areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a foldable roof assembly having a softpanel top cover that seals against a hard top portion of the roof.

BACKGROUND OF THE INVENTION

Foldable stowable roof soft tops are commonly used in sport-utilityvehicles for recreational purposes. The foldable roof is typically movedbetween a stowed position, and a deployed position. When in the deployedposition, the foldable roof protects the occupants of the vehicle fromvarious weather conditions. The foldable roof also includes varioussections which are made of a clear material to essentially function as awindow, allowing the occupant of the vehicle to see outside of thevehicle. However, there are occasions where the weather is pleasant, andit is desired by the occupants of the vehicle to move the foldable roofto an open position such that the vehicle essentially functions withoutpart of a roof or essentially functions without a roof, and thepassenger compartment of the vehicle is exposed to the atmosphere. Thisallows the occupants of the vehicle to enjoy more favorable weatherconditions while driving.

An alternative to the convertible soft top is to use a hard top that isbulky and does not provide any open air feel without removing the entiretop. If the entire hard top is removed, it then must be stored, which isoften difficult because of the size of the top. Other convertible roofsuse a hard top that is large and bulky and does not provide any open airfeel without removing two front top panels, which is also laborious,difficult, time consuming, and ergonomically disadvantageous. If one ormore of the front top panels are removed, they then must also be stored,which is often difficult because of the size weight of the panels. Whilethis will give the occupant an open air feel, the panels are large andbulky. If the occupant wants to gain the open air feel they need to exitthe vehicle and remove the panels using multiple knobs and latches andthen store the panels. This makes for a time consuming operation as wellas a potential storage issue due to the size of the panels. They arealso hard to handle due to their size and weight and due to the factthey must be installed and removed over the operators head. In the eventof inclement weather, the panels also cannot be quickly put back inplace.

Accordingly, there exists a need for a more manageable and easilyfoldable top made of soft material to provide a top that can be openedquickly to provide what is often referred to as an open air feel, wherea portion of the top of the roof is moved from a closed or deployedposition to an open or stowed position exposing a portion of the insidevehicle cockpit/passenger compartment to the outside without removingthe top.

SUMMARY OF THE INVENTION

The present invention is directed to a foldable roof assembly having asoft panel top assembly that is in sealing engagement with a hard topportion of the roof. The soft panel top assembly has a pivotal portionthat is lightweight and folds back without the operator needing to leavethe vehicle to give the occupant a quick and easy sunroof/open airfeeling in the front cockpit. This is done more easily than with typicaltwo-panel hard top systems that are more time consuming to disengagefrom the vehicle and are bulky to handle and remove. The presentinvention also eliminates storage issues since the soft panel top foldsback rather than having to be removed entirely and stored as withconventional hard top panels.

The soft panel top assembly has two door rails connected to side sportbars of the vehicle providing a sealing surface for the doors of thevehicle as well as pivot points for the pivotal portion of the softpanel top assembly. The soft panel top assembly has two side raillinkage assemblies connected to a first bow member that is secured to awindshield frame with quick release latches. Each side bow linkageassembly is connected to opposing ends of a fixed bracket connected tothe respective door rail creating the pivot points with the use of thebrackets. The soft panel top assembly includes a rear header that is acloseout for sealing engagement with an existing seal of the hard toproof portion. The soft panel top assembly is made lightweight by using alighter rear header, e.g., rear header closeout that is a wireframeand/or lightweight molded section(s), and by using minimal framing andmostly soft goods. This further helps with ease of installation and easeof cycle efforts of the pivotal portion. Further, the assembly ismountable to the vehicle without any modification, drilling of holes, orany other change to existing hardware and structure to the vehicle otherthan the removal of the manufacturers existing front cockpit panels.

In another embodiment, the rear header portion of the soft panel topassembly includes at least one bulb seal. When the rear header portionis installed on the vehicle the existing seal of the hard top roofportion is compressed, and the bulb seal of the soft panel top assemblycontacts at least one surface of the hard top roof portion, the existinghard top seal, and also a binding edge of the rear header portion. Thiscreates a weatherproof seal between the soft and hard top portions. Atleast one tertiary seal is also provided along the length of the rearheader portion as a back-up weather resistant seal.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a soft panel top cover assembly in aclosed position with the fabric cover removed for clarity connected to avehicle and in sealing engagement with a hardtop portion, in accordancewith the present invention;

FIG. 2 is a top plan view of the soft panel top cover assembly of FIG.1;

FIG. 3 is a bottom plan view of the soft panel top cover assembly ofFIG. 1;

FIG. 4 is a top plan view of the soft panel top cover assembly of FIG. 1in a closed position;

FIG. 5 is a top plan view of FIG. 1 with the soft panel top coverassembly shown in an open position;

FIG. 6 is a right perspective view of the soft panel top cover assemblyof FIG. 1 with a pivotable portion in an open position;

FIG. 7 is a side elevation view of the soft panel top cover assembly ofFIG. 1 in an open position;

FIG. 8 is a left perspective view of the soft panel top cover assemblyin an open position;

FIG. 9 is a side elevation view of the soft panel top cover assembly ofFIG. 1 in a closed position;

FIG. 10 is a side elevation view of a side rail linkage assembly in aclosed position;

FIG. 11 is an enlarged side elevation view of the side rail linkageassembly in an open position;

FIG. 12 is a perspective view of the soft panel top cover assembly in anopen position;

FIG. 13 is a perspective view of the soft panel top cover assemblyshowing the pivotable portion in a partially open position;

FIG. 14 is a side elevation of a fabric management bow;

FIG. 15 is a perspective view of an attachment bracket coupled to ahardtop flange and a rear header of the soft panel top cover assembly;

FIG. 16 is a perspective view of the cover coupled to the rear header,in accordance with an embodiment of the present invention;

FIG. 17 is a perspective view of a portion of a soft panel top coverassembly that is connected to the vehicle having a bulb seal in sealingengagement with a hardtop portion, in accordance with another embodimentof the present invention;

FIG. 18 is a bottom perspective view of a rear header assembly connectedto a soft top cover of the soft panel top cover assembly and depictingthe bulb seal of FIG. 17 and a tertiary seal, in accordance with thepresent invention;

FIG. 19 is a cross sectional view of the rear header assembly of thesoft panel top cover assembly in an installed position on the vehicle,with the top cover omitted for clarity, depicting a hard top cover sealof the hard top portion compressed and the bulb seal in a sealingposition, in accordance with the present invention;

FIG. 20 is a cross sectional view of the rear header assembly of thesoft panel top cover assembly depicting the hard top cover seal and bulbseal prior to compression, in accordance with the present invention;

FIG. 21 is a bottom perspective view of the rear header assemblyconnected to the fabric cover, in accordance with the present invention;

FIG. 22 is a bottom perspective view of a rear header portion of therear header assembly comprising three segments connected together, inaccordance with the present invention;

FIG. 23 is a bottom perspective view of a first outer segment of therear header portion connected to a center segment of the rear headerportion, in accordance with the present invention;

FIG. 24 is a bottom perspective view of the rear header portion, inaccordance with the present invention; and

FIG. 25 is a top perspective view of a rear header portion comprisingfive segments, in accordance with another embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring generally to FIGS. 1-16, there is provided a soft panel topassembly generally shown at 12 that is foldable and sealable with a hardtop roof portion generally shown at 14. The soft panel top assembly 12is connected to a vehicle 16. The vehicle 16 includes a windshield frame18 with side members 20, e.g., sport bars, extending therefrom and across bar or cross member 91 operably connecting the side members 20substantially adjacent the rear of the driver/passenger compartment.

The soft panel top assembly 12 folds back to give the occupant a quickand easy open air effect, e.g., lightweight and easily operated at ashort interval stop, without completely removing the soft panel topassembly 12 from the vehicle 16. Folding the soft panel top assembly 12between a closed position and an open position is also achievablewithout the occupant needing to leave the vehicle and eliminates removaland storage of roof panels from the vehicle. Once cycled to the openposition, the soft panel top assembly 12 also does not require strappingthe assembly down to maintain open air positioning. Further, the softpanel top assembly 12 includes built in stops 10, e.g., bump stops, toprevent over cycling past the desired open position.

The soft panel top assembly 12 has a pivotal portion indicated generallyat 24 (FIGS. 7 and 13) for pivoting the soft panel top assembly 12between the deployed or closed position and a stowed or open position.The assembly 12 geometry generally follows the hardtop 14 contours andseals against the hardtop's bulb seal. When the soft panel top assembly12 is cycled between the closed/open position, the soft panel topassembly 12 remains in the sealing engagement with the hard top roofportion's 14 bulb seal, generally indicated at sealing portion 26. Whenthe soft panel top assembly 12 is in the closed position the soft paneltop assembly 12 also seals with the vehicle windshield frame's 18 bulbseal.

The soft panel top assembly 12 has at least two door rails 28 eachoperably connected to a respective side sport bar 20 of the vehicle 16.The door rails 28 provide a sealing surface shown generally at 29 forthe driver/passenger doors 13 of the vehicle 16 as well as pivot pointsfor the pivotal portion 24 of the soft panel top assembly 12. Each doorrail 28 has a plurality of clamping surfaces (FIG. 6), including, atleast one pair of clamping surfaces 30 forming an upper surfaceextending inwardly over the top of the sport bar 20 and a bottom surfaceextending inwardly under the bottom of the sport bar 20. The pair ofclamping surfaces 30 attach the front portion of the door rails 28 tothe vehicle 16 using threaded mushroom knob fasteners 32 extendingthrough the pair of the clamping surfaces 30 with the sport bar 20sandwiched therebetween. Another of plurality of clamping surfaces is arear clamping surface 31 extending inwardly under the bottom of thesport bar 20 to attach the rear portion of the door rails 28 to thevehicle 16 using threaded knob fasteners extending through the rearclamping surface 31 and rear header, as will be explained in greaterdetail below, with the sport bar 20 sandwiched therebetween.

At least one bracket 34 is fixedly connected by fasteners to both of thetwo door rails 28 to pivotably connect the pivotal portion 24 to thedoor rails 28. The brackets 34 provide at least a forward pivot point 36and rearward pivot point 37 for the pivotal portion 24 of the soft paneltop assembly 12.

The pivotal portion 24 of the soft panel top assembly 12 has two siderail linkage assemblies generally shown at 38 (FIG. 10), each includingthe bracket 34, a first link 40, a second link 42 and a third link 44.The first link 40 is fixedly connected to a header 46 or first bowmember. The other end of the first link 40 is pivotably connected to thebracket 34 at the forward pivot point 36. The second link 42 ispivotably connected to the first link 40 at a third pivot point 48. Theother end of the second link 42 is pivotably connected to the third link44 at a fourth pivot point 50. The third link 44 is also pivotablyconnected to the bracket 34 at the rearward pivot point 37.

A bushing and screw arrangement 52 provides for all of the respectivepivotal connections such that the side rail linkage assemblies 38 freelypivot to allow the top to be cycled open or closed. However, alternativepivot joint mechanisms can be used without departing from the scope ofthe invention depending on the particular application.

The pivotable portion 24 also has a first fabric management bow 54fixedly connected to the third links 44 by a plurality of fasteners 56.The soft panel top assembly 12 is also provided with a second fabricmanagement bow 58 fixedly connected to a rear header portion 60. Thesecond fabric management bow 58 does not move with opening/closing ofthe assembly 12. Rather, the second bow 58 is operably connected withfasteners, e.g. bolted, in sockets or recesses formed in the rear header60. The first and second management bows 54, 58 extend in the cross carposition. The combination of linkage assemblies 38 with the fabricmanagement bows 54, 58 manages the top cover 62 as the soft panel topassembly 12 folds to the open position, which is yet another significantadvantage (FIGS. 12-13). The fabric management bows 54, 58 also minimizefabric movement in the closed position, which will act to alleviate windflap noise, in addition to managing fabric during operation and in theopen position.

Preferably, the ends of the first link 40 of the side rail linkageassemblies 38 extend into the first bow member 46 and are securedthereto with a second fastener 64. At least one fastener 64 is usedwhich in this embodiment is a nut and bolt combination, but it is withinthe scope of the invention that other fasteners, such as rivets, may beused as well.

The first bow 46 is adapted for releasable attachment to the windshieldframe 18 for opening and closing the soft panel top assembly 12. Thefirst bow 46 has at least attachment mechanisms 66, e.g., latches orother suitable attachment mechanism, connected thereto that have a handactuated clamping arrangement to selectively connect to the windshieldframe 18. The first bow 46 is preferably molded plastic with steelreinforcement on the bottom and comprises two attachment mechanisms 66,most preferably, latches, which when in the closed position attach toopposing features, e.g., metal loops 67, generally located under thevisors of the vehicle, and when cycling to the open position, travelwith the first bow 46. The attachment mechanisms 66 provide for securingclosure of the top to the existing windshield frame 18 and are readilyreleased by an operator for opening of the soft panel top assembly 12.

In accordance with a preferred embodiment, the third link 44 has atleast one first curved portion generally indicated at 68 (FIG. 10), and,the first link 40 has at least one second curved portion generallyindicated at 70. Generally, the bracket 34 has at least one raisedportion generally indicated at 72 to position the rearward pivot point37 at a predetermined height. The linkage assemblies 38 also include thelimiting stop 10 feature operable to keep the soft panel top assembly 12a predetermined distance away from the hard top 14. The combination ofthe linkage assembly 38 geometry, link geometries, and limiting stops 10coordinate to provide the height needed for the pivotal portion 24 tolay above and near the hard top portion 14 without touching the top 14when in the open position. Thus, there is a predetermined clearancegenerally shown at “A” between the linkage assembly 38 and the hard topportion 14 and a predetermined clearance indicated generally at “B”between the third link 44 and hard top portion 14 to prevent scratchesor damage.

The limiting stop 10 is generally triangular, e.g., generally aright-angle triangle shape and/or scalene triangle, and is connected tothe first link 40 for movement with the first link 40 between a stowedstop condition (FIG. 10) and deployed stop condition (FIG. 11) where avertex of the limiting top 10 contacts the fixed bracket 34 to hold thefirst link 40 at an angle for keeping the pivotal portion 24 off thesurface of the hard top portion 14.

The first fabric management bow 54 is connected to an inwardlyprojecting attachment portion 74 of the first link 40 by the pluralityof fasteners 56. The fasteners used in this embodiment are a nut andbolt combination, but it is within the scope of the invention that otherfasteners, such as rivets, may be used as well. The top cover 62 isconnected to the first fabric management bow 54. In accordance with oneembodiment, the first fabric management bow 54 is a round bow thatslides into a pocket sewed into the top cover 48. In accordance withanother embodiment, an extrusion is stitched or sewn onto the top cover48.

In accordance with a preferred embodiment the first fabric managementbow 54 and second fabric management bow 58 have a channel 76 (FIG. 10)along the length of the bows 54, 58 that is open on at least one end toreceive an extrusion. The extrusion is connected to the top cover 62,e.g., bonded or adhered thereto with adhesive, and/or sewn, etc, and theextrusion is slid into the channel 76. The channel 76 is generallycircular in cross section, or any other alternative cross sectionssuitable for attaching the cover 62 to the bows 54, 58.

A first fabric management bow 78 having a preferred channel 80 crosssection is illustrated in FIG. 15 according to another embodiment. Theextrusion includes a larger portion 84, e.g., larger diameter bulbousportion, received within an inner chamber of the channel 80 such thatthe extrusion 84 cannot work its way out laterally through a smalleropening 82 of the channel 80. At least one, preferably two, flanges 86generally extend from the larger bulbous portion for attachment to thetop cover 62, e.g., bonded or adhered thereto with adhesive, and/orsewn. After the cover 62 is attached the extrusion 84 is slid into thechannel 80 along the length of the channel 80 and the first fabricmanagement bow 78 is then connected to the attachment portion 74 of thefirst link 40 and the plurality of fasteners 56 applied. The secondfabric management bow 58 is identical in this embodiment to the firstfabric management bow 78.

Depending on the application the extruded materials are generallypolypropylene, polyethylene, flexible polyvinyl chloride, structuralacrylonitrile butadiene styrene, thermoplastic elastomer of operabledensities or other material suitable for making the extrusion (bulbportion and attachment flange). If more than one extruded material isused the extruded materials are compatible materials to melt bond to oneanother under pressure depending on the application.

The rear header 60 has a plurality of attachment features for couplingto the sports bars 20, cross member 91, and hard top cover portion 14.At least two locating brackets 88 are connected to the bottom of therear header 60 by at least two fasteners 93 (FIG. 15). The locatingbrackets 88 interface with the hardtop 14. In particular, the locatingbrackets 88 have a portion that fits under a portion of the existinghardtop structure at the leading edge flange 89 toward the corners.

At least two feet 90 are integrally formed with the bottom of the rearheader 60 and rest on top of the cross member 91. The feet 90 include alocating lip 92 that hangs over the front edge of the cross member 91generally toward the center of the vehicle. These feet 90 generally setthe height with the hardtop 14.

The rear header 60 also includes two attachment members 94 that areintegrally formed with the header and attached to the top of opposingsport bars 20 by second mushroom knobs 96. The first and second mushroomknobs 32, 96 are most preferably the same type of knob andinterchangeable. The two attachment members 94 are a predeterminedlength and can be longer or shorter without departing from the scope ofthe present invention.

Thus, the rear header 60 is operably attached to the sports bars in twolocations on the cross member 91, in two locations (1 per side) on thefore/aft sport bars 20, and interfaces with the hardtop 14 using the twolocating brackets 88. No modification to the hardtop 14, no drilling ofany holes, or changing of any existing components is required. Themanufactures front cockpit panels are removed and the soft panel topassembly 12 is installed. In a preferred embodiment, the soft panel topassembly 12 ships as a module except that the two locating brackets 88are connected to the underside of the rear header 60 and extends tounder the hardtop 14 leading edge flange. Alternatively, the brackets 88are also shipped attached. The process for installation of the softpanel top assembly 12 includes removing existing top and then aligningthe clamping surfaces 30 of the two door rails 28 with the sport bars 20adjacent apertures for the mushroom knobs 32, aligning the attachmentmembers 94 of the rear header 60 on top of the sports bars 20 adjacentapertures for the second mushroom knobs 96, and/or resting the two feet90 of the rear header 60 on top of the cross member 91. The threadedmushroom knobs 32, 96 are turned to attach the soft panel top assembly12 to the sport bars 20. The two locating brackets 88 are positionedalong the leading edge flange 89 and bolted to the underside of the rearheader 60 using pre-drilled holes in the rear header 88. At least twothreaded fasteners 106 extend from the bottom of the cross member 91and/or speaker bar into pre-drilled holes on the underside of the rearheader. The knobs clamp against the respective surfaces and have a pinportion extending into the respective components. As the respectiveknobs are tightened and screwed into the cross member 91 and sports bars20 of the vehicle 16, the knobs connect the assembly 12 to the vehicleand also press the rear header 60 against the hard top cover seal 26

The rear header 60 is a rear header closeout operable to engage at leastone seal existing on the hard top portion 14 to provide a weatherproofseal under compression, e.g., bulb seal, gasket or other suitable sealto prevent leaks between the hard top portion 14 and assembly 12. It iswithin the scope of the invention to manufacture the rear header 60 as awireframe (e.g., bent wire frame welded together), lightweight moldedplastic, or other suitable lightweight material and configurationsand/or combinations thereof suitable to withstand predetermined strengthrequirements and to sealingly engage with the hard top portion 14,depending on the particular application without departing from the scopeof the invention. The rear header 60 is a single piece or plurality ofpieces. Most preferably, the rear header 60 has three lightweight moldedpieces operably connected together.

In a preferred embodiment, a plastic retainer 108 slides over a metalbacking 110 piece connected by a fastener to keep the cover 62 connectedon the rear header 60, e.g., the cover is sandwiched. Similarly, thefront header 46 has a similar metal backing and plastic retainerconnecting the cover 62 to the header 46, e.g., the cover is sandwiched.The cover is also stitched or sewn 112 along edges. The cover 62 or softskin or top cover of the soft panel top assembly 12 is fabric. The cover62 is secured to the rear header 60 and front header 46 without the needfor snaps.

Most preferably, the seal 26 of the hard top portion 14 is a bulb seal.The seal 26 generally follows the contour toward the front of the hardtop portion 14, e.g., a forward projecting stepped portion of the hardtop with the seal operably attached along a top surface thereof. Therear header 60 geometry generally follows the hard top portion 14contours and seals against the hardtop's bulb seal 26.

The soft panel top cover assembly 12 also has a cable assembly 98located on both side that are fore/aft cables to provide tension alongthe sides of the fabric (FIG. 9). The cable 98 is operably connected tothe header 46 and also to the rear header 60.

The soft panel top cover assembly 12 also has a plurality of seals. Atleast two front corner seals 100 (FIG. 5) are operably connected, e.g.,with adhesive, toward the forward end of the door rails 28 near awindshield seal. At least two front header seals 104 are operablyconnected, e.g., with adhesive, near both ends of the header 46. Atleast two rear corner seals 102 are operably connected, e.g., withadhesive, toward the rearward end of the door rails 28 near the rearheader 60 (FIG. 6). Optionally, a lip seal is operably connected to thecover 62 along at least the rear edge surface of the rear header 60. Byway of example, the lip seal is sewn and/or bonded to the cover 62 andsandwiched between the cover 62 and rear header 60 at the rear of theassembly 12 near the current hardtop seal 26.

The seals 100,102,104 are an open cell foam, a closed cell foammaterial, EPDM (ethylene propylene diene monomer), TPE (thermoplasticelastomers), TPV (thermoplastic vulcanizate), etc., a foam rubber, anextruded rubber, a formed/molded rubber mucket, and/or a siliconematerial. The seals 100,102,104 are preferably foam seals, mostpreferably soft sponge EPDM closed cell foam. Alternatively, at leastone of the pairs of seals 100,201,104 are a rubber mucket which is morerobust.

The left half of the soft panel top cover assembly 12 and correspondingfeatures are substantially mirror image/symmetrical to the right half ofthe soft panel top cover assembly 12 and corresponding features depictedin the figures.

Referring now to FIGS. 17-25, in accordance with another embodiment ofthe present invention, there is provided a soft panel top assembly 200similar to the soft panel top assembly 12 in FIGS. 1-16 (e.g., isconnected to the vehicle 16, is foldable and sealable with the hard toproof portion 14, and includes the pivotable portion 24 with the two siderail linkage assemblies 38 and fabric management bows 54, 58, the twodoor rails 28 and the front header 46, etc.). However, the rear headerof the soft panel top assembly 200 additionally includes at least oneseal, preferably, a sealing system or arrangement with multiple seals.In addition, the soft panel top assembly 200 has a lightweight rearheader portion that is a single piece or a plurality of pieces operablyconnected together.

The soft panel top assembly 200 includes a rear header assembly showngenerally at 202 having a sealing system indicated generally at 204 toprevent leaks between the hard top portion 14 and assembly 200. Thesealing system 204 includes at least one rear header seal 206, whichseals in cooperation with the existing at least one hard top seal 208 onthe hard top portion 14. At least one tertiary seal 210 is alsoprovided. The tertiary seal 210 is preferably a continuous strip thatruns the length of the rear header 202.

The hard top seal 208 is typically a triangular bulb seal, however, anyother seal is contemplated. It is also contemplated that the presentinvention includes at least one additional seal, e.g., bulbous seal(s),applied to the hard top portion 14 prior to installation of the rearheader assembly 202.

The rear header seal 206 is connected to an upper rear header 212 of therear header assembly 202. The rear header seal 206 is a bulb seal,living hinge seal, and any other seal suitable for sealing engagementwith the hard top roof portion 14. At least one retainer 214 is operablyconnected to the inside rear edge of the soft top cover 48 of theassembly 200 and is located against the inner surface of the upper rearheader 212. A portion of the retainer 214 projects rearward to receiveat least one binding retainer 216 or binding, generally having a C-shapeor U-shape, along the edge of the retainer 214. An attachment portionshown generally at 218 of the rear header seal 206 is held between theretainer 214 and the binding 216. A sealing portion shown generally at220, preferably a bulb portion, of the rear header seal 206 becomessandwiched between and seals against a surface 222 of the hard topportion 14 and the binding edge 224.

Most preferably, the retainer 214, binding 216 and rear header seal 206are continuous parts that generally run the cross car length of the rearheader assembly 202 and generally follow the contour of the rear edge ofthe rear header upper 212. The rear header assembly 202 geometrygenerally follows the contours of and seals against the hard top portion14.

FIG. 20 illustrates a cross sectional view depicting the sealing system204 before installation of the rear header assembly 202, thus, prior tocompression of the hard top seal 208 and at least one other hard topseal 226 by the rear header assembly 202. The top 228 of the binding216, cover 48 material, retainer 214, rear header seal 206 and the lowersection 230 of the binding 216 that sandwiches the components togetheris depicted. The rear header seal 206 can additionally, oralternatively, be bonded or attached with adhesive, and/or othersuitable attachment method without departure from the scope of thepresent invention. A plurality of fasteners is also contemplated. FIG.20 also depicts an alternative attachment method where the top andbottom of the binding 228,230, attachment portion of the seal 206 withinthe binding 216, retainer 214 and cover 48 are sewn together 232. In apreferred embodiment, the rear header seal 206 is held in the desiredpositions by being sandwiched between parts and with adhesive.

FIG. 19 illustrates a cross sectional view depicting the sealing system204 sealing the soft panel top assembly 200 to the hard top portion 14.When the rear header assembly 202 is installed to the vehicle 16 thehard top seal 226, e.g., flange seal, on the hard top portion 14 iscompressed by a bottom surface on a rear header lower 213 of the rearheader assembly 202. The rear header lower and upper 212,213 arepreferably integrally formed. In addition, when the rear header assembly202 is installed to the vehicle 16 the hard top seal 208, e.g.,triangular bulb seal, on the hard top portion 14 is compressed by therear header assembly 202 which pushes the sealing portion 220, e.g.,bulb, of the rear header seal 206 upward between the binding 216 and thehardtop. Thus, once compressed, the sealing portion 220 is in contactwith the hardtop surface 222, which is generally a vertical surface, andin contact with the binding edge 224, which is generally a verticalsurface, as well as in contact with the hard top seal 208.

The existing hard top seal 208 is rubber. At least the sealing portion220 of the rear header seal 206 of the present invention is generallyless stiff than the hard top seal 208. The rear header seal 206 has apredetermined durometer for meeting the desired sealing withrequirements. Having a first durometer, e.g., of a higher durometer, forthe attachment portion 218 and a second durometer, e.g., of a lowerdurometer, for the sealing portion 220 is contemplated without departingfrom the scope of the present invention.

Generally, the rear header seal 206 is an open cell foam, a closed cellfoam material, such as, but not limited to, EPDM, TPE, TPV, etc., a foamrubber, an extruded rubber, a formed/molded rubber mucket, and/or asilicone material. Preferably, the rear header seal 206 is a closed cellfoam material. The tertiary seal 210 preferably uses similar material.

The left half of the soft panel top cover assembly 200 and correspondingfeatures are substantially mirror image/symmetrical to the right half ofthe soft panel top cover assembly 200 and corresponding featuresdepicted in the figures.

The rear header assembly 202 includes a rear header portion 234 that isa single piece or plurality of pieces. The rear header portion 234 is alightweight header including a wireframe (e.g., bent wire frame weldedtogether), lightweight molded plastic, or other suitable lightweightmaterial and configurations and/or combinations thereof depending on theparticular application. Preferably, the rear header portion 234 is threeto five pieces, e.g., molded segments, operably connected together. Mostpreferably, the rear header portion 234 has three lightweight moldedpieces operably connected together.

Referring to FIGS. 22-24, there is depicted a rear header portion 234that is a 3-piece header, according to an embodiment of the presentinvention. A center segment 236, first outer segment 238 and a secondouter segment 240 are provided. The first and second outer segments 238and 240 are operably connected toward the ends of the center segment236. It is understood that more or less than three segments arecontemplated depending on the application without departing from thescope of the present invention. The rear header portion 234 is a singleunit or any plurality of parts that combine to make the rear header.

Referring more particularly to FIG. 23, the end 242 of the first outersegment 238 overlaps the end 244 of the center segment 236. A rib 246 isalso received in a slot 248, e.g., to allow the overlap and buildingstrength at the area of connection 250. The respective segments aremechanically fastened using at least one fastener 252, e.g., screws,rivets, bolts, or any other suitable fastener to hold the segmentstogether. Alternatively, or additionally, the segments are bondedtogether or adhesive is used.

Referring more particularly to FIG. 25, there is depicted a rear headerportion 334 that is a 5-piece header, according to another embodiment ofthe present invention. A center segment 336, first outer segment 338,second outer segment 340, first intermediate segment 342 and secondintermediate segment 344. The first and second outer segments 338 and340 are operably connected toward the outermost ends of the firstintermediate 342 and second intermediate segment 344, respectively. Thefirst and second outer segments 342 and 344 are operably connectedtoward the ends of the center segment 336. The respective segments aremechanically fastened using at least one fastener as described above,e.g., screws, rivets, bolts, or any other suitable fastener to hold thesegments together. Alternatively, or additionally, the segments arebonded together or adhesive is used.

It is understood that the present invention is additionally suitable fora two door or four door vehicle.

By utilizing the pivot points attached to the door rails this allows theoperator to quickly cycle the top from the closed position to the opensunroof position without removing the top. The operator would then beable to cycle the top from the open position to the closed position andlatch the top just as easily. The operator does not need to leave thevehicle in order to operate the top. The whole top is made lightweightby using the rear header (wireframe and/or molded rear header) and byusing minimal frame and mostly soft goods. This helps with ease ofinstallation and ease of cycle efforts. The soft panel top assemblyenables the occupant to fold the top back to gain an open air experiencewithout removing the top and can mount to the hardtop withoutmodification to the vehicle. The soft panel top assembly has significantbenefits over typical removable hard top cockpit panels and does notrequire modification to the vehicle or hard top roof portion in any way.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the essence of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A soft top insert for a vehicle roof forinserting into an open space in the roof defined by a windshield frame,side members extending back therefrom over oppositely-disposed driverside and passenger side vehicle doors, and a cross member connecting theside members opposite the open space from the windshield frame andbehind the doors, the insert including: at least two door rails adaptedto be attached to the side members of the vehicle; a pivotable portionthat is pivotable with respect to the at least two door rails; a headerconnected to the pivotable portion and adapted to selectively connect tothe windshield frame; a rear header assembly adapted to be operablycoupled to the side members and the cross member, said rear headerassembly including a sealing system adapted to engage with a hardtoproof portion to provide a weather tight seal, said sealing systemincluding a tertiary seal to provide a back-up weather resistant seal;and a roof top opening cover, said cover operably connected to theheader and rear header, wherein pivoting the pivotable portion allowsthe cover to move between a closed position and an open position.
 2. Thesoft top insert of claim 1, further comprising at least one seal on therear header assembly that is pressed between the hard top roof portionand the rear header assembly.
 3. The soft top insert of claim 1, whereinwhen the rear header assembly is installed onto the vehicle, the rearheader assembly is adapted with an abutment surface for abutment with atleast one rear header seal.
 4. The soft top insert of claim 2, whereinthe at least one seal is selected from the group consisting of open cellfoam, a closed cell foam material, ethylene propylene diene monomer,thermoplastic elastomers, thermoplastic vulcanizate a foam rubber, anextruded rubber, a formed/molded rubber mucket, and a silicone material.5. The soft top insert of claim 2, wherein the at least one seal is aclosed cell foam and less stiff than the at least one hard top seal. 6.The soft top insert of claim 1, wherein the tertiary seal is acontinuous strip along the length of the rear header assembly to providea back-up weather resistant seal.
 7. The soft top insert of claim 1,wherein the rear header assembly further comprises: at least one upperrear header; at least one retainer operably connected to the cover andto the upper rear header; at least one rear header seal having anattachment portion and a sealing portion, said sealing portion beingbulbous; at least one binding retainer operably connected to the atleast one retainer and to the attachment portion of the at least onerear header seal such that the at least one retainer and the attachmentportion are sandwiched together operable to retain the at least one rearseal; wherein the at least one binding retainer, attachment portion andbinding retainer are sewn together, bonded, and/or adhered together; andwherein said sealing portion is located substantially between thebinding retainer and the hard top roof portion and in contact with theat least one hard top seal to provide the weather tight seal.
 8. Thesoft top insert of claim 7, wherein the rear header assembly isadditionally adapted to be in sealing engagement with at least one otherseal of the hard top portion to provide a weather tight seal.
 9. Thesoft top insert of claim 1, wherein the rear header assembly includes arear header portion that is a lightweight wireframe and/or moldedmaterial that is a single piece or a plurality of pieces operablyconnected together.
 10. The soft top insert of claim 9, wherein the rearheader portion is three to five pieces operably connected together by atleast one fastener, bonded and/or with adhesive.
 11. The soft top insertof claim 9, wherein the rear header portion is three molded piecesoperably connected together by at least one fastener, bonded and/or withadhesive.
 12. The soft top insert of claim 1, wherein the pivotableportion further comprises two side rail linkage assemblies to provide apivotable connection adjacent to the two door rails and allow the coverto move between a closed position and an open position.
 13. The soft topinsert of claim 12, further comprising at least one bracket, wherein thelinkage assemblies are connected adjacent the two door rails to provideat least one pivot point on each of the two door rails.
 14. The soft topinsert of claim 12, wherein the pivotable portion further comprises: afirst fabric management bow operably connected between the two side raillinkage assemblies and to the cover to manage fabric of the cover duringmovement of the cover between the open and closed positions and tominimize fabric movement when the soft panel top assembly is in theclosed position; and a second fabric management bow operably fixedlyconnected to a rear header portion to at least minimize fabric movementwhen the soft panel top assembly is in the closed position.
 15. The softtop insert of claim 12, wherein the side rail linkage assemblies eachfurther comprise: a first link fixedly connected to the header, saidfirst link also pivotably connected to one of said brackets at a pivotpoint on the bracket, said first link pivotable about the pivot point; athird link pivotably connected to the bracket at a rearward pivot pointon the bracket, said third link pivotable about the rearward pivotpoint; a second link pivotably connected to the first link first link ata third pivot point, said second link also pivotably connected to thethird link at a fourth pivot point, a limiting stop operably connectedto one of the links; wherein the bracket, first link, second link, andthird link arrangement coordinates pivotable movement of the pivotableportion between the open and closed positions, and the limiting stopprevents the pivotable portion, other than the cover, from contactingthe hard top roof portion to prevent damage.
 16. The soft top insert ofclaim 1, further comprising: at least one front corner seal affixed toeach door rail; and/or at least one rear corner seal affixed to eachdoor rail; and/or at least two front header seals affixed to the ends ofthe header to provide weather resistant seals.
 17. The soft top insertof claim 1, further comprising: a pair of opposing clamping surfacesprovided on each of the two door rails to attach a front portion of eachdoor rail to a respective sport bar; and a rear clamping surfaceprovided on each of the two door rails to attach a rear portion of eachdoor rail to the respective sport bar.
 18. A soft top insert for avehicle, comprising: two door rails adapted to be attached to sidemembers of the vehicle; two side rail linkage assemblies; two brackets,wherein a respective bracket is adapted to be connected adjacent to arespective one of the two door rails for a pivotal connection to arespective one of the two side rail linkage assemblies with respect toeach door rail; a header connected between the two side rail linkageassemblies and adapted to selectively connect to a windshield frame; arear header assembly adapted to be in sealing engagement with a hard toproof portion to provide a weather tight seal; a rear header sealoperably connected on the rear header assembly to provide a weathertight seal between the rear header assembly, a substantially verticalsurface on the hard top roof portion, and an existing hard top sealprovided on the hard top portion, said rear header assembly operable toalso compress another seal on the hard top portion to further provide aweather tight seal; a tertiary seal operably connected on the rearheader assembly along the length of the rear header assembly to providea back-up weather tight seal; and a cover that is a soft skin roof topcover, said cover operably connected to the header, rear header assemblyand two side rail linkage assemblies, where pivoting the two side raillinkage assemblies allows the cover to move between a closed positionand an open position.
 19. The soft top insert of claim 18, wherein therear header assembly includes a rear header portion that is alightweight wireframe and/or molded material that is formed of a singlepiece or a plurality of pieces operably connected together.
 20. A softtop insert for a vehicle roof for inserting into an open space in theroof defined by a windshield frame, side members extending backtherefrom over oppositely-disposed driver side and passenger sidevehicle doors, and a cross member connecting the side members oppositethe open space from the windshield frame and behind the doors, theinsert including: two door rails adapted to be attached to the sidemembers of the vehicle, each door rail including a sealing surfaceoperable to allow a weather resistant seal with the front doors of thevehicle; a pivotable portion pivotable with respect to the at least twodoor rails; a header connected to the pivotable portion and adapted toselectively connect to the windshield frame; a rear header assemblyadapted to be operably coupled to the side members and the cross member,said rear header assembly including a sealing arrangement adapted to bein sealing engagement with at least one hard top seal of a hardtop roofportion to provide a weather tight seal, wherein said sealingarrangement has at least one bulb seal and a tertiary seal, wherein therear header assembly includes a lightweight molded material and has reargeometry which is adapted to follow the contour of the hardtop roofportion and to seal the sealing arrangement against the hard top portionand the at least one hard top seal; a cover that is a soft skin roof topcover, said cover operably connected to the header and rear header,where pivoting the pivotable portion allows the cover to move between aclosed position and an open position; and a plurality of clampingsurfaces provided on each door rail extending toward the vehicleinterior when installed, for connecting each of said two door rails to arespective one of the side members of the vehicle using a respectivefastener, wherein the side members are fore/aft sport bars.